Catalytic reactor and method for providing a catalytic reaction

Abstract

A catalytic reactor (22) is disclosed that includes a central axis (A) and a stack of catalytically active sheets (10). The catalytically active sheets (10) are axially stacked. Each of the catalytically active sheets (10) includes a central opening (17), and at least some of the catalytically active sheets (10) include axially extending flanges (18) disposed at least partially around the central opening (17), the flanges (18) of one catalytically active sheet (10) extending into the central opening (17) of an adjacent catalytically active sheet (10). A method of providing a catalytic reaction is also disclosed.

Description

[Technical Field]

[0001] The present invention relates to a catalytic reactor and a method for providing catalytic reactions. More specifically, the present invention relates to a catalytic reactor comprising a stack of catalytically active sheets. Catalytic reactors are used for various types of chemical reactions, including combustion, catalytic partial oxidation, catalytic reforming, autothermal reforming, hydrogenation, selective oxidation, etc. For example, this type of catalytic reactor can be used for the combustion of gaseous fuels, such as natural gas, propane, butylene, or similar gases, or mixtures of different types of gaseous fuels. [Background technology]

[0002] Several different types of catalytic reactors are known in the prior art. One type of catalytic reactor is disclosed in U.S. Patent No. 5,623,999, which describes a catalytic reactor in which the gas to be reacted is conducted through catalytically active nets arranged in series.

[0003] One problem with prior art catalytic reactors and methods for providing catalytic reactions is that they are inefficient.

[0004] Another problem with such prior art catalytic reactors and methods is that they are inflexible and difficult to size according to different applications and process parameters.

[0005] Another problem with such prior art catalytic reactors and processes is that they do not use catalytically active materials efficiently, requiring vast amounts of such catalytically active materials. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] International Publication No. 97 / 02092 Summary of the Invention [Problem to be solved by the invention]

[0007] It is an object of the present invention to overcome or at least alleviate one or more of the problems of prior art catalytic reactors and methods for providing catalytic reactions. [Means for solving the problem]

[0008] The present invention relates to a catalytic reactor comprising a central shaft and a stack of catalytically active sheets, the catalytically active sheets being stacked axially, each of the catalytically active sheets having a central opening, and at least some of the catalytically active sheets having an axially extending flange disposed at least partially around the central opening, the flange of one catalytically active sheet extending into the central opening of an adjacent catalytically active sheet. The central opening, in combination with the flanges of the catalytically active sheets, allows a first reactant to be guided axially along the stack and distributed radially along the catalytically active sheets to react with a second reactant, the second reactant being axially directed, for example, radially outside the central opening. This invention thus provides an efficient reactor in which the concentration of the first reactant is higher near the central opening and lower radially outward. In this way, the reactor is flexible and can be used for different types of reactions and adapted to different process parameters. For example, the catalytic reactor can be used for combustion, catalytic partial oxidation, catalytic reforming, autothermal reforming, hydrogenation, selective oxidation, etc. The reactor structure allows for efficient use of the catalytically active material in the catalytically active sheet, for example, the first reactant may be a fuel, such as a mixture of gaseous fuels in the form of biofuel, and the second reactant may be air or oxygen, and an efficient reactor for the combustion of such a mixture of fuels is achieved.

[0009] Each of the catalytically active sheets may include a radially extending portion extending radially from the central opening. The radially extending portion of one catalytically active sheet may be spaced apart from the radially extending portion of an adjacent catalytically active sheet. Thus, a first reactant can be distributed along the radially extending portion of the catalytically active sheet into the gap for efficient reaction with a second reactant.

[0010] The flange may be tapered towards its free end so that the catalytically active sheets can be stacked in an efficient manner, for example by providing gaps between radially extending portions of adjacent catalytically active sheets.

[0011] The catalytically active sheets may be arranged in a mesh structure, such as wire mesh, perforated plate material, expanded metal, etc., such that the first reactant can be guided axially through the stack by cooperating flanges, while some of the first reactant is guided radially through the flanges in a balanced manner by openings in the mesh structure. The flanges and radially extending portions may be formed in the mesh structure. Thus, the second reactant can be efficiently guided axially through the radially extending portions of the stack. For example, the entire catalytically active sheet may be formed in the mesh structure.

[0012] Alternatively, the catalytically active sheets may be formed of a plate material such as sheet metal, and the flanges may be provided with holes and / or the radially extending portions may be provided with through apertures distributed around a central opening. Thus, a first reactant may be guided axially through the stack by the cooperating flanges, while some of the first reactant is guided radially through the flanges in a balanced manner by the holes in the flanges. A second reactant may be efficiently guided axially through the radially extending portions of the stack by the apertures to react with the first reactant guided radially outward along the radially extending portions and into the gaps.

[0013] The stack of catalytically active sheets, or at least the central opening, may be plugged at one end. By plugging the central opening or stack at the end opposite the end where the first reactant is introduced, efficient distribution of the first reactant within the stack is achieved. The first reactant is guided axially through the stack by cooperating flanges, and by plugging the end, the first reactant is forced radially.

[0014] The catalytically active sheet may comprise a substrate and a ceramic layer bonded to the substrate, the ceramic layer having pores filled with catalytically active material. The catalytically active sheet may also comprise particles of a first material and a second material having a higher melting point than the first material, the ceramic layer being bonded to the substrate via the first material and the particles of the second material partially embedded in the first material and protruding into the ceramic layer. In this way, the ceramic layer is formed with a pore structure containing the catalytically active material.

[0015] The catalytic reactor may include a reaction vessel having an inlet for a first reactant, at least one inlet for a second reactant, and at least one outlet, wherein a stack of catalytically active sheets is disposed within the reaction vessel, the inlet for the first reactant being disposed at one end of the stack and aligned with a central opening in the catalytically active sheet, and at least the central opening being blocked at an opposite end of the stack.

[0016] The present invention also relates to a method of providing a catalytic reaction, said method comprising: a) feeding a first reactant axially into a central opening of one catalytically active sheet of a stack of catalytically active sheets; b) directing some of the first reactant through axially extending flanges disposed at least partially around some of the openings and extending axially into the central opening of adjacent catalytically active sheets; c) directing some of the first reactant radially outward from the flange and into contact with a second reactant to provide the catalytic reaction; Includes:

[0017] A method for producing a catalytically active sheet is also disclosed, the method comprising: a) providing a substrate; b) depositing particles of a first material and a second material onto the substrate, the particles of the second material having a higher melting point than the first material; c) heating the substrate with the first material and the particles to a temperature that melts the first material but does not melt the particles of the second material, thereby adhering the first material and the particles to the substrate, the particles being partially embedded in the first material and forming a roughened surface; d) depositing a ceramic material onto the roughened surface to form a ceramic layer thereon; e) adding catalytically active material to said ceramic layer; Includes:

[0018] The method for producing a catalytically active sheet allows for easy and efficient production of the catalytically active sheet. The method allows for the production of the catalytically active sheet without a thermal spray process. The combination of the first material and the particles allows for safe, reliable, and efficient fixing of the ceramic layer to the substrate to produce the catalytically active sheet.

[0019] The method can include providing particles of the first material and / or the second material as one or more suspensions, optionally combining both materials and providing them as a suspension. Thus, the first material and / or the second material can be deposited on the substrate in an efficient manner, such as by spraying or other coating processes, and the suspensions can be deposited at any suitable temperature, such as room temperature. Thus, the first material can be deposited on the substrate without first melting it. The method can then include heating the substrate having the particles of the first material and the second material thereon in a furnace, such as a vacuum furnace, or using a reducing or inert gas, to melt only the first material and bond it to the substrate while fixing the particles to the first material. Thus, the first material and the particles can be produced in an efficient and reliable manner, efficiently forming an attachment layer for subsequent fixing of the ceramic layer.

[0020] After fixing the first material to the substrate by melting it, the method can include depositing a ceramic layer by providing a ceramic material as a suspension and depositing the suspension, for example by spraying, onto the first material containing the particles, so that the ceramic material is formed in an easy manner and partially surrounds the particles protruding from the first material, and mechanically securely fixes the ceramic layer to the substrate, for example by drying and firing.

[0021] Further features and advantages of the invention will become apparent from the following description of embodiments, the accompanying drawings and the dependent claims. [Brief explanation of the drawings]

[0022] By way of example, embodiments of the invention will now be described with reference to the accompanying drawings, in which:

[0023] [Figure 1] 1 is an enlarged schematic cross-sectional view of a portion of a catalytically active sheet according to the present invention. [Figure 2] 2A-2D are a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a first embodiment. [Figure 3] 2A-2D are a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a first embodiment. [Figure 4] 2A-2D are a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a first embodiment. [Figure 5] 2A-2D are a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a first embodiment. [Figure 6] 2A-2D are a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a first embodiment. [Figure 7] 2 is a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a second embodiment. [Figure 8] 2 is a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a second embodiment. [Figure 9] 2 is a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a second embodiment. [Figure 10] 2 is a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a second embodiment. [Figure 11] 2 is a series of schematic cross-sectional views of a method for manufacturing the catalytically active sheet of FIG. 1 according to a second embodiment. [Figure 12] 1 is a schematic diagram of a catalytically active sheet according to one embodiment, the catalytically active sheet being arranged with flanges and arranged in the form of a mesh. [Figure 13] FIG. 13 is a schematic side view of the catalytically active sheet of FIG. 12. [Figure 14] FIG. 13 is a schematic side view of the stack of catalytically active sheets of FIG. 12. [Figure 15] 3 is a schematic illustration of a catalytically active sheet according to another embodiment, the catalytically active sheet being in the form of an apertured plate with holes in the flanges. [Figure 16] FIG. 16 is a schematic side view of the catalytically active sheet of FIG. [Figure 17] FIG. 16 is a schematic side view of the stack of catalytically active sheets of FIG. 15. [Figure 18]1 is a schematic cross-sectional view of a catalytic reactor according to a first embodiment of the present invention. [Figure 19] 19 is a schematic cross-sectional view of the catalytic reactor according to FIG. 18, showing the flow of reactants and products within the catalytic reactor. [Figure 20] FIG. 2 is a schematic cross-sectional view of a catalytic reactor according to a second embodiment of the present invention. [Figure 21] 21 is a schematic cross-sectional view of the catalytic reactor according to FIG. 20, showing the flow of reactants and products within the catalytic reactor. DETAILED DESCRIPTION OF THE INVENTION

[0024] Referring to FIG. 1, a catalytically active sheet 10 according to the present invention is shown schematically. The catalytically active sheet 10 is configured to be used to promote chemical reactions. For example, the catalytically active sheet 10 may be arranged for combustion, refining, catalytic reforming, etc. For example, the catalytically active sheet 10 may be arranged to purify flue gases of carbon monoxide and / or hydrocarbons such as VOCs and PAHs. For example, the catalytically active sheet 10 may be part of a reactor and arranged in a reaction vessel for chemical reactions, as described below. For example, the catalytically active sheet 10 may be included in a reactor for the combustion of gaseous fuels such as natural gas, propane, butylene, or similar gases, or a mixture of different fuels, for example, for heating purposes.

[0025] The catalytically active sheet 10 includes a substrate 11, a first material 12, particles 13 of a second material, a ceramic layer 14 including a ceramic material having pores 15, and a catalytically active material 16. The first material 12 and the particles 13 form an attachment layer on the substrate 11. For example, the first material 12 is disposed directly on the substrate 11, with the particles 13 being partially embedded within the first material 12 and protruding from its surface. The ceramic layer 14 is disposed on top of the attachment layer formed by the first material 12 and the particles 13, and the ceramic layer 14 engages with the particles 13. Thus, the attachment layer formed by the first material 12 and the particles 13 is disposed between the substrate 11 and the ceramic layer 14.

[0026] According to one embodiment, the catalytically active sheet 10 is formed as a mesh structure, i.e., a mesh structure with a plurality of through holes. For example, the substrate 11 is formed as a wire mesh, grid, or the like. Alternatively, the substrate 11, and thus the catalytically active sheet 10, may be formed as a perforated plate sheet, as will be described in more detail below. For example, the substrate 11 is or includes a metal or alloy. According to one embodiment, the substrate is made of steel, such as stainless steel, aluminum, or copper. Alternatively, the substrate 11 is made of a polymeric material, such as polytetrafluoroethylene or a similar polymer, or a composite material that can withstand relatively high temperatures. Generally, the substrate 11 should be able to withstand temperatures of at least 350°C. In some cases, it should be able to withstand temperatures much higher than this level, such as at least 500°C, at least 700°C, or at least 900°C.

[0027] A first material 12 is disposed on a substrate 11 that forms a base structure. The substrate 11, or at least a portion or side thereof, is coated with the first material 12. In the illustrated embodiment, the top surface of the substrate 11 is coated with the first material 12. Alternatively, both sides, the entire surface, or the entire substrate 11 may be coated with the first material 12. For example, the first material 12 is a metal or alloy. For example, the first material 12 is Al or a similar metal with a relatively low melting point. Alternatively, the first material 12 is an alloy including a metal, such as Ni, Cu, Fe, and / or steel, and a melting point depressant.

[0028] The particles 13 are partially embedded in the first material 12 and at least partially protrude away from the substrate 11. The particles 13 are made of or include a second material having a higher melting point than the first material 12. For example, the solidus temperature of the second material particles 13 is higher than the liquidus temperature of the first material 12. For example, the second material particles 13 include a metal powder, a ceramic powder, or a mixture thereof. The particles 13 may have different shapes and sizes. The particles 13 are provided in or on the first material 12 to add surface roughness that aids in adhesion of the ceramic layer 14. For example, the particles 13 have a particle size of at least 10 μm, or at least 20 μm, e.g., 20-100 μm. For example, the second material has a porosity of at least 30%.

[0029] The ceramic layer 14 is provided on the attachment layer formed by the first material 12 and the particles 13 and is secured thereto by the particles 13. Thus, the particles 13 are partially embedded in the first material 12 and partially embedded in the ceramic layer 14, mechanically securing the ceramic layer 14 to the substrate 11. Thus, the ceramic layer 14 is disposed on the first material 12 and the particles 13 protruding therefrom. The ceramic layer 14 may comprise alumina, zirconia, titanium dioxide, silica, tungsten carbide, silicon nitride, or a similar ceramic, or a mixture thereof. Pores 15 are formed in the ceramic layer 14 to increase the surface area for depositing the catalytically active material 16 therein. Thus, the ceramic layer 14 is provided with the catalytically active material 16, and the catalytically active material 16 is disposed within the pores 15. For example, the catalytically active material 16 may be a noble metal, a transition metal, or a mixture or oxide thereof. For example, the catalytically active material 16 may be palladium.

[0030] Referring also to FIGS. 2-6, a method for producing a catalytically active sheet 10 is illustrated in a series of diagrams according to a first embodiment. The substrate 11 has been described above and is illustrated schematically in FIG. 2. The substrate 11 is coated with a first material 12, for example, by a spraying process. A substrate 11 having the first material 12 is illustrated in FIG. 3, where the first material 12 is provided as a layer on the substrate 11. According to one embodiment, the first material 12 is provided as a suspension, i.e., the first material 12 is provided as particles dispersed in a liquid such as water. For example, the substrate 11 is coated with the first material 12 by a spraying process, where the first material 12 is sprayed onto the substrate 11 at room temperature, for example. Therefore, the first material 12 is not heated or sprayed at an elevated temperature. Alternatively, the first material 12 can be applied to the substrate 11 by another coating process, such as painting or dipping. Alternatively, the first material 12 can be provided as a paste, which is applied to the substrate 11 by spreading the paste over the surface of the substrate 11. After applying the first material onto the substrate, the substrate 11 with the first material 12 is optionally dried, for example by heat treatment in an oven.

[0031] After coating the substrate 11 with the first material 12, particles 13 containing a second material are provided on the first material 12, as shown in FIG. 4. For example, the particles 13 may be provided as a suspension, also called a slurry, in which the particles 13 are suspended in a liquid such as water. The suspension of particles 13 is then applied to the first material 12 supported by the substrate 11. For example, the particles 13 may be applied to the first material 12 by a spraying process, in which the suspension containing the particles 13 is sprayed onto the first material 12. Thus, the particles 13 may be sprayed onto the first material 12 at room temperature. After applying the particles 13 to the first material 12, the substrate 11 carrying the first material 12 and particles 13 may be dried, for example, in an oven. The substrate 11 carrying the first material 12 and particles 13 is then heat-treated, for example, in a furnace, to a temperature that melts the first material 12 but does not melt the particles 13 of the second material. The substrate 11 is also not melted. Thus, the first material 12 is fixed to the substrate 11 by melting while fixing the particles 13 to the first material 12. The particles 13 are mechanically fixed to the first material 12, and the particles 13 are partially embedded in the first material 12 after melting of the first material 12. The first material 12 is also mechanically bonded to the substrate by melting into the roughness of its surface. Particles 13 partially embedded in and protruding from the first material 12 are shown in FIG. 4. For example, the heat treatment to melt the first material 12 is performed under vacuum in a vacuum furnace. Alternatively, the heat treatment to melt the first material 12 is performed using a reducing or inert gas in a furnace.

[0032] The substrate 11 carrying the first material 12 and particles 13 is then provided with a ceramic layer 14, as shown in FIG. 5. The ceramic layer 14 is provided on the particles 13 and the first material 12, such that the first material 12 is disposed between the ceramic layer 14 and the substrate 11. For example, the ceramic layer 14 is deposited on the attachment layer 12 as a slurry, such as an aqueous suspension. The ceramic layer 14 may also include a pore-forming agent to form a porous structure in the ceramic material. Typically, the thickness of the ceramic layer is in the range of 0.1 to 0.8 mm, preferably 0.2 to 0.5 mm. The ceramic layer 14 has an enlarged surface formed by pores 15, which are configured to hold catalytically active material 16, as shown in FIG. 6.

[0033] The ceramic layer 14 may be fabricated by the following processes: 1) direct spraying with secondary surface area expansion by precipitation; or 2) spraying with simultaneous deposition of ceramic powder; or a combination of methods 1) and 2), followed by coating with catalytically active material 16 through an impregnation process. Alternatively, the pore former may be a combustible material that can be burned by heat treatment. Optionally, the pore former may be a pore-forming polymeric material. Alternatively, the ceramic layer 14 is a ceramic powder containing particles with a high specific surface area. For example, pores 15 are formed in the ceramic layer 14 by conventional methods.

[0034] The pores 15 of the ceramic layer 14 are configured to support the catalytically active material 16. For example, the pores 15 may be cylindrical. In this way, the chemical to be purified can easily reach the catalytically active material 16 of the catalytically active sheet 10. The catalytically active material 16 may be deposited in the pores 15 of the ceramic layer by, for example, a conventional impregnation process. During impregnation, the structure of the pores 15 of the ceramic layer 14 is saturated with, for example, a solution containing the catalytically active material 16. The catalytically active material 16 may include a noble metal, a transition metal, or a combination thereof.

[0035] Referring to FIGS. 7-11, an alternative embodiment of the present invention is described in which a substrate 11 is coated with a mixture of a first material and particles 13 of a second material. A substrate 11 having a mixture of a first material 12 and particles 13 is shown in FIG. 7. For example, the first material 12 may also be provided as particles, and the first material 12 and particles 13 of the second material may be provided as a mixture in a slurry. A slurry containing both the first material 12 and particles 13 of the second material is applied to the substrate 11, as described above, for example, by spraying. Thus, the slurry may be provided on the substrate by spraying at room temperature. The substrate 11 containing the slurry is then optionally dried. After coating the substrate 11 with the mixture of the first material 12 and particles 13, the substrate 11 is heated to melt the first material 12 but not the substrate 11 or the second material, resulting in the particles 13 adhering to the first material 12 and the first material 12 adhering to the substrate 11, as shown in FIG. 8. Thus, the particles 13 are partially embedded in the first material 12 and protrude away from the substrate 11, providing a rough outer surface for securing the ceramic layer 14 as described above. The ceramic layer 14, which may be provided as a slurry, is then deposited on the first material 12 and the particles 13, as shown in FIG. 9. For example, the ceramic layer may be deposited by spraying, as described above. Next, as shown in FIG. 10, the ceramic layer 14 may be subjected to a surface area enlargement treatment to form pores 15. For example, the ceramic layer 14 may include a pore-forming agent. Finally, the catalytically active material 16 is deposited, for example, by impregnation. The catalytically active material 16 may be deposited on the surface of the ceramic layer 14 and inside its pores 15.

[0036] The particles are provided in first material 12 to add surface roughness that aids in the adhesion of subsequently deposited ceramic layer 14. In other words, providing first material 12 with rough particles can provide an increased surface area for improved adhesion of ceramic material 14 to substrate 11. Upon heating, first material 12 fuses to substrate 11, exposing contained particles 13. Exposing particles 13 allows ceramic layer 14 to be secured to substrate 11 due to the increased surface area and roughness provided by particles 13.

[0037] 12 and 13, catalytically active sheets 10 according to one embodiment of the present invention are shown schematically, and FIG. 14 shows a stack of such catalytically active sheets 10. While FIG. 14 shows four identical catalytically active sheets 10, the stack may include any suitable number of catalytically active sheets 10, which need not be identical. For example, catalytically active sheets 10 are arranged with at least a substrate 11 and a catalytically active material 16, and optionally one or more of a ceramic layer 14, a first material 12, and a second material 13. For example, catalytically active sheets 10 are arranged as described above with reference to FIG. 1.

[0038] The catalytically active sheet 10 is arranged to have an axis A, a through central opening 17, a central flange 18 disposed at least partially around the central opening 17 and extending at least partially axially, and a radially extending portion 19. In the illustrated embodiment, the central opening 17 is circular. Alternatively, the central opening 17 may be oval or rectangular, or formed in another suitable shape. In the illustrated embodiment, the flange 18 is continuous and surrounds the entire periphery of the central opening 17. Alternatively, the flange 18 may be interrupted or arranged as two or more tabs distributed around the periphery of the central opening 17.

[0039] 13 and 14 , the flange 18 extends axially, and the radially extending portion 19 extends radially from the base of the flange 18. For example, the base of the flange 18 is connected to the radially extending portion 19 and terminates at a free end. For example, the base and / or free end of the flange 18 may be annular, e.g., having a circular cross-section, although the flange 18 or at least its base may have a shape corresponding to other shapes of the central opening 17. At least a portion of the flange 18 can be inserted into the flange 18 of an adjacent catalytically active sheet 10, as shown in FIG. 14 . For example, the flange 18 tapers toward its free end, and the free end of the flange 18 can be inserted into the base of the flange 18 of an adjacent catalytically active sheet. Thus, the diameter or cross-sectional area of ​​the base of the flange 18 is larger than that at its free end. For example, the flange 18 may be conical, more specifically, frustoconical.

[0040] In the illustrated embodiment, the radially extending portion 19 extends radially from the base of the flange 18. For example, the radially extending portion 19 is a sheet or sheet portion having a central opening 17. For example, the radially extending portion 19 extends from the central opening 17 to the peripheral edge of the catalytically active sheet 10 and is a free end, and the outer periphery of the radially extending portion 19 also forms a free periphery and is free of the catalytically active sheet 10. In the illustrated embodiment, the radially extending portion 19 is flat, extending only radially and perpendicular to the axis A throughout its entire length. Alternatively, the radially extending portion 19 extends partially radially and is inclined with respect to the axis A, such that the radially extending portion 19 tapers toward the central opening 17. Alternatively, the radially extending portion 19 is formed with various structures, such as dimples, corrugations, or the like, and optionally conforms to a similar shape of an adjacent catalytically active sheet 10. Thus, the catalytically active sheets 10 are stackable. For example, as shown in Figure 14, the catalytically active sheets 10 are formed so that the flanges 18 contact each other when stacked and the radially extending portions 19 are spaced apart from each other. For example, the catalytically active sheets 10 are stacked and then pressed together. In the embodiments of Figures 12 to 14, the catalytically active sheets 10 are arranged in a mesh structure, such as a wire mesh, net or grid structure, a perforated sheet or an expanded metal sheet. For example, the mesh openings are 2 mm or less, e.g., 0.1 to 2 mm.

[0041] In the illustrated embodiment, all catalytically active sheets 10 in the stack are arranged with flanges 18. Alternatively, at least some of the catalytically active sheets 10 include axially extending flanges 18, with the flange 18 of one catalytically active sheet extending into the central opening 17 of an adjacent catalytically active sheet 10. For example, every other catalytically active sheet 10 in the stack of sheets includes a flange 18. For example, the flanges 18 cooperate to form a central tube through the stack.

[0042] Referring to FIGS. 15 and 16, a catalytically active sheet 10 according to another embodiment of the present invention is shown schematically, and FIG. 17 shows a stack of such catalytically active sheets 10. The catalytically active sheets 10 according to FIGS. 15-17 differ from the catalytically active sheets of FIGS. 12-14 in that they are not formed in a mesh structure but are formed from a continuous sheet, such as sheet metal or other suitable sheet material. The catalytically active sheet 10 is arranged with an axis A, a through central opening 17, a central flange 18, and radially extending portions 19. In the embodiment of FIGS. 15-17, the axially extending flanges 18 form a conduit, as seen in FIG. 17. Thus, each flange 18 is provided with at least two, or at least four or six, through-holes 20, such as holes 20, distributed around the circumference of the flange 18 and connecting the conduit formed by the flange 18 with the space defined by the gaps between the radially extending portions 19. Further, the radially extending portion 19 is arranged with through apertures 21, such as at least two or at least four or six through apertures 21, distributed around the central opening 17. In FIG. 16, two apertures 21 are shown with dashed lines. For example, the through apertures 21 are arranged between the central opening 17 and the periphery of the radially extending portion 19. For example, the apertures 21 of adjacent catalytically active sheets 10 are aligned. In the illustrated embodiment, the apertures 21 are distributed around the central opening 17 in the same manner as the holes 20, and the apertures 21 and holes 20 are arranged at the same radial angle relative to the axis A. For example, the extension of the central axis of the holes 20 intersects the corresponding extension of the central axis of the aperture 21. The apertures 21 are arranged to provide axial flow, and the holes 20 are arranged to provide substantially radial flow. For example, the holes 20 are arranged so that the radial flow intersects the axial flow through the apertures 21. In the illustrated embodiment, the apertures 21 extend in a radial plane. Optionally, the apertures 21 are larger than the holes 20. In the drawings, the apertures 21 and the holes 20 are circular, but they may have other shapes, such as oval, rectangular or other suitable shapes. The holes 20 are arranged so that they are not blocked when the catalytically active sheets 10 are laminated.According to one embodiment, the holes 20 are located closer to the base of the flange 18 than to the free end of the flange.

[0043] 18 and 19, a catalytic reactor 22 according to a first embodiment is shown schematically. The catalytic reactor 22 comprises a stack of catalytically active sheets 10. Each catalytically active sheet 10 has a central opening 17, and at least some of the catalytically active sheets in the stack have axially extending flanges at least partially disposed around the central opening 17, with the flanges 18 of one catalytically active sheet 10 extending into the central opening 17 of an adjacent catalytically active sheet 10. In FIGS. 18 and 19, the catalytically active sheets 10 are shown in a mesh structure. For example, the catalytically active sheets 10 may be arranged as described with reference to FIGS. 12-14. Alternatively, the catalytically active sheets 10 may be formed of a plate material having apertures 21 in radially extending portions 19, with at least some of the catalytically active sheets 10 being formed with flanges 18 having holes 20, as described with reference to FIGS. 15-17.

[0044] In the illustrated embodiment, the catalytic reactor 22 includes an optional reaction vessel 23, and the stack of catalytically active sheets 10 is disposed inside the reaction vessel 23. The reaction vessel 23 is disposed with an inlet 24 for a first reactant. For example, the first reactant is a fuel, such as a gas fuel. According to one embodiment, the first reactant is a fuel mixture. The inlet 24 for the first reactant is disposed to direct the first reactant to the central opening 17 of the catalytically active sheet 10. For example, the inlet 24 for the first reactant is aligned with the central opening 17. In the illustrated embodiment, the inlet 24 for the first reactant is disposed at a first end of the reaction vessel 23, for example, in the center of the first end. The reaction vessel 23 is disposed with one or more inlets 25 for a second reactant. For example, the second reactant is air or oxygen. For example, the reactor vessel 23 may include at least two, or at least four, or six or more inlets 25 for the second reactant disposed radially outward of the inlet 24 for the first reactant. In the embodiment of FIGS. 18 and 19, the inlet 25 for the second reactant is disposed at the first end of the reactor vessel 23, i.e., at the same end as the inlet 24 for the first reactant. The inlets 25 for the second reactant are distributed around the inlet 24 for the first reactant. For example, if applicable, the inlets 25 for the second reactant may be aligned with the apertures 21 in the radially extending portions 19 of the catalytically active sheets 10. The reactor vessel 23 may also be provided with one or more outlets 26 for the products. For example, the products may be combustion gases, including, for example, carbon dioxide. In the illustrated embodiment, the outlets 26 are disposed radially outward of the stack of catalytically active sheets 10, but may be disposed at any suitable location. The second end of the reaction vessel 23 is plugged, or at least the end of the stack of catalytically active sheets 10 opposite the first reactant inlet 24 is plugged.

[0045] Referring to FIG. 19, the flow of the first and second reactants and the product is shown schematically. The first reactant is directed axially into the central opening 17 of the catalytically active sheets 10, as indicated by the arrow R1. The first reactant is directed axially into the central opening 17 at one end of the stack of catalytically active sheets 10. For example, the first reactant R1 may be directed into the reaction vessel 23 through the first reactant inlet 24. Alternatively, the first reactant may be directly directed into the central opening 17 at one end of the stack. The first reactant R1 is guided through the central opening 17 by the flange 18 to the opposite, blocked end of the stack of catalytically active sheets 10, and the first reactant is forced radially outward through the mesh or holes 20 of the flange 18, and radially through the gaps between the radially extending portions 19 of the catalytically active sheets 10, for example. A portion of the flow of the first reactant is further guided axially by the flange 18, and a portion of the flow is forced radially outward. For example, when a predetermined pressure is achieved inside the reaction vessel 23, the first reactant is forced radially outward. The radial flow of the first reactant further outward through the flange 18 is indicated by the arrows. At the same time, the second reactant is directed axially through the radially extending portion 19, for example, by the radially extending portion 19 formed of a mesh material or through its apertures 21; the axial flow of the second reactant is indicated by the arrow R2. For example, the second reactant R2 is directed into the reaction vessel 23 through the second reactant inlet 25. The first reactant is forced radially and then collides with the axial flow of the second reactant R2, and the first and second reactants react to form a product. The product is then directed from the reaction vessel 23 through the outlet 26. Thus, the concentration of the first reactant is higher near the central opening 17 and the flange 18 than further outward, and the concentration of the first reactant decreases radially. At the same time, the concentration of the second reactant is radially higher in the stack of catalytically active sheets 10, e.g., the radial level at which it is supplied to the stack of catalytically active sheets 10. For example, the concentration of the second reactant increases radially between the flange 18 and the radial level at which the second reactant is introduced.The concentration of the product naturally increases radially outward.

[0046] 20 and 21, a second embodiment of a catalytic reactor 22 is shown schematically, in which an inlet 25 for a second reactant is located at the second end of the reactor vessel 23, opposite the first end and opposite the inlet 24 for the first reactant. The inlet 25 is located radially outward of the central opening 17. Thus, the second reactant is introduced into the stack of catalytically active sheets 10 in an axial direction opposite that of the first reactant, as indicated by arrow R1 for the first reactant and arrow R2 for the second reactant. The central opening 17 at the opposite end of the stack is blocked as the first reactant is introduced, forcing the first reactant radially into contact with the flow of second reactant R2 and forming products as described above. Alternatively, the second end of the reactor vessel may be blocked away from the inlet 25 for the second reactant, forcing the first reactant radially.

[0047] The inlet 25 for the second reactant is described above as a plurality of inlets distributed about the axis A of the stack of catalytically active sheets 10. Alternatively, the second reactant may be introduced into the radially extending portion 19 at one end of the stack through an annular orifice or annular inlet extending radially outward of the central opening 17.

Claims

1. A catalytic reactor (22) comprising a central axis (A) and a stack of catalytically active sheets (10), the catalytically active sheets (10) being stacked in an axial direction, each of the catalytically active sheets (10) having a central opening (17), the catalytically active sheets (10) having an axially extending flange (18) disposed at least partially around the central opening (17), the axially extending flange (18) of one catalytically active sheet (10) extending into the central opening (17) of an adjacent catalytically active sheet (10); the axially extending flange (18) extends in the axial direction, and each of the catalytically active sheets (10) includes a radially extending portion (19) extending radially from a base of the axially extending flange (18); the base of the axially extending flange (18) is connected to the radially extending portion (19) and terminates in a free end; a diameter or cross-sectional area of ​​the base of the axially extending flange (18) being larger than a free end of the axially extending flange (18), such that at least a portion of the axially extending flange (18) can be inserted into the axially extending flange (18) of an adjacent catalytically active sheet (10).

2. 2. The catalytic reactor of claim 1, wherein each of said catalytically active sheets (10) includes a radially extending portion (19) extending radially from said central opening (17).

3. 3. The catalytic reactor according to claim 2, wherein the radially extending portion (19) of one catalytically active sheet (10) is arranged with a gap between it and the radially extending portion (19) of an adjacent catalytically active sheet (10).

4. 4. Catalytic reactor according to claim 2 or 3, wherein the radially extending portion (19) is flat.

5. 4. A catalytic reactor according to claim 2 or 3, wherein the radially extending portion (19) extends from the central opening (17) to the periphery of the catalytically active sheet (10).

6. A catalytic reactor according to any one of claims 1 to 3, wherein said flange (18) is tapered towards its free end.

7. A catalytic reactor according to any one of claims 1 to 3, wherein the flange (18) extends continuously around the entire central opening (17).

8. The catalytic reactor according to any one of claims 1 to 3, wherein the flange (18) is provided with through holes (20).

9. 4. Catalytic reactor according to claim 2 or 3, characterized in that the radially extending portion (19) is provided with through apertures (21) distributed around the central opening (17).

10. Catalytic reactor according to any one of claims 1 to 3, wherein the catalytically active sheet (10) is a mesh.

11. Catalytic reactor according to any one of claims 1 to 3, wherein the catalytically active sheet (10) consists of a plate material.

12. 4. The catalytic reactor according to claim 1, wherein each of the catalytically active sheets (10) comprises a substrate (11) and a ceramic layer (14) bonded to the substrate (11), the ceramic layer (14) having pores (15) in which catalytically active material (16) is supported.

13. 13. The catalytic reactor of claim 12, wherein the catalytically active sheet (10) comprises a first material (12) and particles (13) of a second material having a higher melting point than the first material, and the ceramic layer (14) is bonded to the substrate (11) via the first material (12) and the particles (13) of the second material that are partially embedded in the first material (12) and protrude into the ceramic layer (14).

14. 4. The catalytic reactor according to claim 1, comprising a reaction vessel (23) having an inlet (24) for a first reactant, at least one inlet (25) for a second reactant, and at least one outlet (26), wherein the stack of catalytically active sheets (10) is arranged inside the reaction vessel (23), the inlet (24) for the first reactant being arranged at one end of the stack and aligned with the central opening (17) of the catalytically active sheets (10), at least the central opening (17) being blocked at the opposite end of the stack.

15. 15. The catalytic reactor of claim 14, wherein the inlet (25) for the second reactant is positioned radially outward of the inlet (24) for the first reactant.

16. A method for providing a catalytic reaction in a catalytic reactor (22) according to claim 1, comprising: a) providing a catalytic reactor (22) according to claim 1; b) feeding a first reactant axially into the central opening (17) of one catalytically active sheet (10) of the stack of catalytically active sheets of the catalytic reactor (22); c) guiding some of the first reactant through axially extending flanges (18) disposed at least partially around some of the central openings (17) and extending axially into the central openings (17) of adjacent catalytically active sheets (10); d) directing some of the first reactant radially outward from the flange (18) to contact a second reactant to provide the catalytic reaction; A method for providing a catalytic reaction, comprising:

17. 17. The method of claim 16, further comprising the step of feeding the second reactant axially into the stack of catalytically active sheets (10) at a location radially outward of the central opening (17).

18. 18. A method for providing a catalytic reaction according to claim 17, further comprising the steps of: feeding the first reactant into a reaction vessel (23) through an inlet (24) for the first reactant at one end of the stack of catalytically active sheets (10) in a position aligned with the central opening (17) thereof; and guiding the first reactant radially by blocking at least the central opening (17) at the opposite end of the stack.

Images